Detection device for a cleaning sysytem

ABSTRACT

The present disclosure describes embodiments of a detection device for a cleaning system used in heat exchange systems which comprise a plurality of tubes. The detection device comprises a mounting plate defining a plurality of perforations and a plurality of sensors. Each sensor is being coupled to at least one perforation. In many embodiments of this disclosure, each of the plurality of tubes is operable with a corresponding one of the sensors and during a cleaning process where cleaning balls passage through the plurality of tubes, the cleaning balls are detected by a corresponding one of the sensors.

FIELD OF INVENTION

The present invention relates generally to a detection device for acleaning system for use with heat exchangers for cleaning thereof.

BACKGROUND

Heat exchange systems are used in various industries for a wide varietyof applications such as for heating ventilation and air-conditioning(HVAC) installations. A heat exchange system is an apparatus forfacilitating heat transfer from one medium to another. A tubular heatexchange system is an example of a heat exchange system involving aseries of tubes for the heat exchange process and for suchinstallations, fluid is circulated through the heat exchange system forheat exchange to occur at a bundle of tubes. To achieve optimal heatexchange efficiency, any debris and fouling deposits accumulated at thebundle of tubes must be totally or substantially removed. Taking theheat exchange system off-line for physical flushing is not onlyineffective but also disallow use of the heat exchange system for theduration it remains off-line.

As such, new cleaning systems for use in conjunction with the heatexchange systems use cleaning balls transported by fluid to be fed andcirculated in the heat exchange system. When the cleaning balls passagethrough the bundle of tubes during circulation in the heat exchangesystem, any debris or fouling deposits in the bundle of tubes are pushedout. The cleaning balls are then subsequently retrieved by the cleaningsystem. An example of such cleaning system for use with a plurality oftubes of a heat exchange system comprises a displacement system having afirst port and a second port, a manifold defining a first chamber and asecond chamber, a flow diverting system and at least one cleaning ball.The at least one cleaning ball is configured to passage through theplurality of tubes of the heat exchange system for cleaning thereof.

However, the cleaning systems described above have no means for ensuringand tracking which particular tubes of the plurality of tubes have beencleaned. This may result in some tubes not being cleaned and some tubesbeing cleaned for unnecessary number of times and thus, compromising onthe efficiency of the cleaning system.

Therefore, there is a need for a device or apparatus for addressing theforegoing problems.

SUMMARY

One of the objects of certain exemplary aspects of the presentdisclosure is to address the aforementioned exemplary problems and/or toovercome the exemplary deficiencies commonly associated with the priorart as described herein. Accordingly, for example, provided anddescribed herein are certain exemplary embodiments of exemplaryapparatus, system and method according to the present disclosure whichcan be used for detecting cleaning balls.

According to one aspect of the invention, there is provided a detectiondevice for use with a heat exchanger having a plurality of tubes. Thedevice comprises a mounting plate couplable to the plurality of tubes.The mounting plate defining a plurality of perforations and theplurality of perforations aligned with the plurality of tubes. Theplurality of perforations being shaped and dimensioned to facilitatepassage of at least one of a plurality of cleaning balls therethrough.The device further comprises a plurality of sensors and each sensor ofthe plurality of sensors being coupled to at least one of the pluralityof perforations. Each of the plurality of tubes is operable with acorresponding one of the plurality of sensors and when the plurality ofcleaning balls is introduced into a portion of the heat exchanger forpassage through the plurality of tubes for cleaning thereof, eachcleaning ball passaging through one of the plurality of tubes isdetectable by the corresponding one of the plurality of sensors.

The plurality of tubes of the detecting device defines two extremities.The plurality of tubes defines a plurality of inlets at one of and aplurality of outlets at the other of the extremities.

Further, the mounting plate is being shaped and dimensioned fordisposing onto one of the extremities of the plurality of tubes.

In another aspect of the invention, there is provided a detection devicefor use with a heat exchanger having a plurality of tubes. The pluralityof tubes being demarcated into a plurality of regions, each of theplurality of regions includes at least one tube. The device comprises amounting plate couplable to the plurality of tubes. The mounting platedefines a plurality of perforations where each of the plurality ofperforations is shaped and dimensioned to facilitate fluid communicationwith at least one tube of each region. The plurality of perforationsshaped and dimensioned to facilitate passage of at least one of aplurality of cleaning balls therethrough. The device further comprises aplurality of sensors and each sensor of the plurality of sensors isbeing coupled to at least one of the plurality of perforations. Each ofthe plurality of perforations is operable with a corresponding one ofthe plurality of sensors and when the plurality of cleaning balls isintroduced into a portion of the heat exchanger for passage through theplurality of tubes for cleaning thereof, each cleaning ball passagingthrough a tube of the plurality of tubes is detectable by thecorresponding sensor of the perforation.

The mounting plate of the detection device is formed from at least oneof plastic, graphene, rubber and polytetrafluroethylene (PTFE).

The plurality of sensors being coupled to the at least one of theplurality of perforations includes at least one sensor.

The detection device further comprises a manifold. The manifold iscouplable to the plurality of sensors for one of receiving detectionsignals and electronically communicating with the plurality of sensors.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the disclosure are described hereinafter with referenceto the following drawings, in which:

FIG. 1 is an example of a heat exchanger comprising a plurality oftubes.

FIG. 2A is a detection device comprising a mounting plate defining aplurality of perforations and a plurality of sensors according to someembodiments of the disclosure.

FIG. 2B is a side view of a detection device for use with a heatexchanger according to some embodiments of the disclosure.

FIG. 2C is a detection device being coupled or couplable to a pluralityof tubes according to some embodiments of this disclosure.

FIG. 3A is a top view of a detection device for detecting cleaning ballsregionally according to some embodiments of the disclosure.

FIG. 3B is a first perforation of a detection device for detectingcleaning balls regionally according to some embodiments of thisdisclosure.

FIG. 4A is a top view of a detection device which depicts the couplingand positioning of a plurality of sensors according to some embodimentsof this disclosure.

FIG. 4B is a side view of a detection device which depicts the couplingand positioning of a plurality of sensors according to some embodimentsof this disclosure.

FIG. 5A is a top view of a detection device where a plurality of sensorsis coupled on a top side of the mounting plate according to someembodiments of this disclosure.

FIG. 5B is a side view of a detection device where a plurality ofsensors is coupled on a top side of the mounting plate according to someembodiments of this disclosure.

FIG. 6 shows a configuration of devices for processing of detectionsignals.

FIG. 7 is an example of a detection device in operation based upon FTIRaccording to some embodiments of this disclosure.

DETAILED DESCRIPTION

Representative embodiments of the disclosure for addressing one or moreof the foregoing problems associated with conventional cleaning systemsfor heat exchangers are described hereafter with reference to FIGS. 1 to7. For purposes of brevity and clarity, the description herein isprimarily directed to systems, devices, and techniques for detecting orsensing cleaning balls for cleaning heat exchangers. This, however, doesnot preclude various embodiments of the disclosure from otherapplications where fundamental principles prevalent among the variousembodiments of the disclosure such as operational, functional, orperformance characteristics are required. In the description thatfollows, like or analogous reference numerals indicate like or analogouselements.

Reference will now be made in detail to an exemplary embodiment of thepresent invention, examples of which are illustrated in the accompanyingdrawings. While the invention will be described in conjunction with theembodiment, it will be understood that they are not intended to limitthe invention to these embodiments. On the contrary, the invention isintended to cover alternatives, modifications and equivalents, which maybe included within the spirit and scope of the invention as defined bythe appended claims. Furthermore, in the following detailed descriptionof embodiments of the present invention, numerous specific details areset forth in order to provide a thorough understanding of the presentinvention. However, it will be recognized by one of ordinary skill inthe art that the present invention may be practiced without thesespecific details. In other instances, well-known methods, procedures,components, and circuits have not been described in detail as not tounnecessarily obscure aspects of the embodiments of the presentinvention

Embodiments of this disclosure are directed to sensing or detectiondevices which enable, allow or facilitate detection of cleaning ballsfor cleaning a plurality of tubes of heat exchangers during a cleaningcycle or process. The sensing or detection devices of this disclosureinclude a mounting plate defining a plurality of perforations and aplurality of sensors couplable to the plurality of perforations. Theplurality of sensors being one of coupled to and disposed on theperiphery of the plurality of perforations and by doing so, any cleaningballs passaging a tube of the heat exchanger therethrough will bedetected by a corresponding sensor. By detecting the presence or passageof the cleaning balls, more efficient methodologies for cleaning theheat exchanger can be implemented, resulting in reduced operating cost.For instance, by knowing the number of cleaning balls passaging throughthe plurality of tubes, any upcoming maintenance will concentrate on thetubes where the plurality of cleaning balls passages less frequent andhence operational, time and cost efficiencies can be improved. Theability to detect passage of cleaning balls will enable a user to knowhow many tubes and which particular tubes are stuck with debris. Suchreal time information is useful for a maintenance team to plan andstrategize their tube cleaning schedule, resulting in time efficiency.Further, this ability to detect passage of cleaning balls can result insignificant cost savings in the sense that the maintenance team canperform the cleaning of the tubes as and when required. This is distinctfrom current practices where cleaning of the tubes is performed on ascheduled basis regardless whether the cleaning is necessary or not. Insummary, the detecting devices according to embodiments of thisdisclosure provide efficient cleaning methodologies with significantcost and time savings.

The mounting plate is disposed at one extremity of the plurality oftubes for detecting the cleaning balls and resultantly, any unnecessarydisruptions to the cleaning process for detecting the cleaning balls iseliminated. Additionally, by detecting the presence of cleaning balls,the efficiency in cleaning the heat exchangers can be improved byadopting a targeted or selected cleaning process where the less cleantubes of the heat exchanger can be targeted or selected for cleaning ona more frequent basis. This also ensures that cleaning time andresources are not wasted on the relatively clean exchangers.

As used herein, the detecting or sensing function and any embodiment ofa detecting function in a ‘sensor’ is intended to be construed in itsbroadest context as the capability, for example, but not limited to,sense, detect, measure, indicate, report, feedback or collect, or anycombination thereof, information, presence, status, state or datarelating to cleaning balls and in particular, presence of the cleaningballs.

For purposes of brevity and clarity, descriptions of embodiments of thepresent invention are limited hereinafter to detection devices for usewith heat exchange cleaning systems. This however does not precludeembodiments of the invention where fundamental principles prevalentamong the various embodiments of the invention such as operational,functional or performance characteristics are required.

Description of a Heat Exchanger Operation

An example of a heat exchanger 10 comprising a plurality of tubes 12 isshown in FIG. 1. Depending upon the configuration of the heat exchanger10, the plurality of tubes 12 can include at least three or moreindividual or singular tubes. In such a heat exchanger 10, fluid orrefrigerant is circulated through the heat exchanger 10 by way of eachof the plurality of tubes 12 for heat exchange to occur.

The fluid or refrigerant from a source (not shown) for circulationthrough the plurality of tubes 12 can be fed or channelled through aplurality of inlets 14. The fluid or refrigerant can exit from theplurality of tubes 12 by a plurality of outlets 16. The plurality ofinlets 14 defines a first plurality of openings and the plurality ofoutlets 16 defines a second plurality of openings. Cleaning systems foruse in conjunction with the heat exchanger 10 uses cleaning balls 18transported by fluid to be fed and circulated in the heat exchanger 10.The plurality of cleaning balls 18 is introduced through the pluralityof inlets 14 and can exit from the plurality of tubes 12 by a pluralityof outlets 16.

Detection Device According to Some Embodiments of this Disclosure

FIG. 2A show a detection device 20 according to an embodiment of thisdisclosure. FIG. 2B shows a side view of the detection device 20. Thedetection device 20 facilitates, allows or enables the plurality ofcleaning balls 18 to be detected as the plurality of cleaning balls 18travel through one or more of the plurality of tubes 12. By detectingthe presence or movement of the plurality of balls 18 through one ormore of the plurality of tubes 12, the cleaning system for cleaning theheat exchanger 10 can be made more efficient.

The detection device 20 comprises a mounting plate 22 defining aplurality of perforations 28 and a plurality of sensors 30. The mountingplate 22 includes a first planar surface or a top side 24 and a secondplanar surface or a bottom side 26 outwardly opposing the first planarsurface 24. The top side 24 is substantially parallel to the bottom side26.

Additionally, the plurality of perforations 28 are defined from the topside 24 through the bottom side 26 of the mounting plate 22. Themounting plate 22 is being formed from at least one of plastic, grapheneand rubber. In many embodiments, the mounting plate 22 is being formedfrom a weather and/or heat resistant material such aspolytetrafluroethylene (PTFE). As will be understood by a person ofordinary skill in the related art, the mounting plate 22 can be shapedand dimensioned by way of laser cutting or precision water jet cuttingtechnologies. Similarly, the plurality of perforations 28 can be definedby way of laser cutting or precision water jet cutting technologies. Themounting plate 22 can be of varying thickness, for example, betweenapproximately 5 and 120 mm. In some embodiments, the mounting plate 22is between approximately 20 and 80 mm.

In many embodiments, the mounting plate 22 is couplable to the pluralityof tubes 12. Depending on embodiment details, the mounting plate 22 canbe coupled to the plurality of tubes 12 by one or more mechanicallyattached connections. The term ‘mechanically attached connections’ meansany connection that involves at least one connection that is held inplace by mechanically applied force, stress, pressure, torque, or thelike, such as a threaded connection, a clamped connection, a bolted orscrewed connection. In some embodiments, the mounting plate 22 can bewelded, soldered or adhered to the plurality of tubes 12.

FIG. 2C shows the detection device 20 being coupled or couplable to theplurality of tubes 12. The plurality of tubes 12 defines two extremitieswith the plurality of inlets 14 defining a first extremity and theplurality of outlets 16 defining a second extremity. The plurality ofinlets 14 defines a first plurality of openings and the plurality ofoutlets 16 defines a second plurality of openings. In many embodiments,the mounting plate 22 is being shaped and dimensioned to be disposed onone extremity of the plurality of tubes 12. In many embodiments, themounting plate 22 is disposed such that the bottom side 26 of themounting plate 22 faces the plurality of inlets 14 and is spatiallyaligned with at least a portion of the first plurality of openings ofthe plurality of inlets 14. As will be appreciated by a person ofordinary skill in the art, disposing the mounting plate 22 at the firstextremity of the plurality of tubes 12 provides the advantage that whenfluid or refrigerant displaces through the plurality of tubes 12, theforce or momentum of the fluid or refrigerant will push the mountingplate 22 against the plurality of tubes 12. This prevents the mountingplate 22 from being displaced away from the plurality of tubes 12 when acleaning operation is in process.

In many embodiments of this disclosure, the plurality of perforations 28is aligned with the plurality of tubes 12. The alignment is such thatwhen fluid or refrigerant with the plurality of cleaning balls 18 arecirculated through the plurality of tubes 12, the plurality ofperforations 28 does not impede, obstruct or block the passage of thefluid, refrigerant and/or the plurality of cleaning balls 18 through theplurality of perforations 28. The plurality of perforations 28 is shapedand dimensioned to facilitate passage of at least one of a plurality ofcleaning balls 18 therethrough. Each of the plurality of perforations 28can be of any size and shape, including circle, square, rectangle andtriangle. In some embodiments, each one of the plurality of perforations28 is of the same shape and size. In some other embodiments, theplurality of perforations 28 can be of varying sizes and/or differentshapes. The plurality of perforations 28 can include at least threeperforations.

In many embodiments, each of the plurality of sensors 30 is beingcoupled to at least one of the plurality of perforations 28.Particularly, each of the plurality of sensors 30 being one of coupledto and disposed on or adjacent to the periphery of a correspondingperforation of the plurality of perforations 28. Depending uponimplementation details, at least a portion of the plurality of sensors30 can be embedded within the mounting plate 22. In some embodiments,the at least a portion of the plurality of sensors 30 are embedded alongthe periphery of the corresponding perforation of the plurality ofperforations 28. For such embedded systems, the at least a portion ofthe plurality of sensors 30 may not be visible from the exterior of theperforations. Subsequently, any reference to coupling of the pluralityof sensors 30 to the periphery of a corresponding perforation of theplurality of perforations 28 or of the plurality of sensors 30 beingcoupled to the periphery of a corresponding perforation of the pluralityof perforations 28 includes embedding at least a portion of theplurality of sensors 30 within the mounting plate 22.

Each sensor of the plurality of sensors 30 plays a role in detecting thepresence of the cleaning balls. By coupling or attaching each of theplurality of sensors 30 to at least one of the plurality of perforations28, any cleaning balls entering or exiting a tube of the plurality oftubes 12 can be detected by at least one of the plurality of sensors 30.In many embodiments, each of the plurality of sensors 30 is coupled orattached to at least one of the plurality of perforations 28.Accordingly, each of the plurality of tubes 12 is operable with acorresponding one of the plurality of sensors 30. Upon detection of thecleaning balls 18, the detection signals will be further processed.

From FIG. 2C, it can be seen that a first perforation 28 a is alignedwith a first tube 12 a, a second perforation 28 b is aligned with asecond tube 12 b and a third perforation 28 c is aligned with a thirdtube 12 c. Correspondingly, a first sensor 30 a is coupled to the firstperforation 28 a, a second sensor 30 b is coupled to the secondperforation 28 b and a third sensor 30 c is coupled to the thirdperforation 28 c. By having this configuration, when a plurality ofcleaning balls 18 is introduced into a portion of the heat exchanger 10for passage through the plurality of tubes 12 for cleaning thereof, eachcleaning ball passaging through one of the plurality of tubes isdetectable by the corresponding one of the plurality of sensors 30. Forexample, a cleaning ball 18 a travelling along tube 12 a can passagethrough the first perforation 28 a and as it comes into contact with oris in the proximity of the first sensor 30 a, it will be detected by thefirst sensor 30 a. For clarity, the plurality of perforations 28comprises the first perforation 28 a, the second perforation 28 b andthe third perforation 28 c. The plurality of tubes comprises the firsttube 12 a, the second tube 12 b and the third tube 12 c.

Some embodiments of this disclosure have the capability to detect thepresence of the cleaning balls regionally. This is discussed in thefollowing section.

Detecting Cleaning Balls Regionally

FIG. 3A shows a top view of a detection device 20 being disposed on oneextremity of the plurality of tubes 12 to detect cleaning ballsregionally according to a representative embodiment of this disclosure.The plurality of tubes 12 can be demarcated into a plurality of regions.Each region can include one or more tubes. For example, Region A caninclude the first tube 12 d, the second tube 12 e and the third tube 12f and Region B includes a fourth tube 12 g, a fifth tube 12 h and asixth tube 12 i.

The detection device 20 comprises a mounting plate 22 defining aplurality of perforations 28, namely a first perforation 28 d and asecond perforation 28 e and a plurality of sensors 30, namely a firstsensor 30 d and a second sensor 30 e. Each of the plurality ofperforations 28 is shaped and dimensioned to facilitate fluidcommunication with at least one tube of a region. The plurality ofperforations 28 can be shaped and dimensioned to facilitate passage ofat least one of a plurality of cleaning balls therethrough. Dependingupon embodiment details, the perforation 28 d and/or 28 e can be of anysize and shape including square, circle, rectangle and triangle shapes.The first sensor 30 d is coupled to the first perforation 28 d and thefirst perforation 28 d is shaped and dimensioned for fluid communicationwith the first tube 12 d, the second tube 12 e and the third tube 12 f.In a similar fashion, the second sensor 30 e is coupled to the secondperforation 28 e and the second perforation 28 e is shaped anddimensioned for fluid communication with the fourth tube 12 g, the fifthtube 12 h and the sixth tube 12 i. In many embodiments, each sensorbeing one of coupled to and disposed on or adjacent to the periphery ofeach perforation. Depending upon implementation details, at least aportion of the plurality of sensors 30 can be embedded within themounting plate 22. In some embodiments, the at least a portion of theplurality of sensors 30 are embedded along the periphery of eachperforation of the plurality of perforations 28. For such embeddedsystems, the at least a portion of the plurality of sensors 30 may notbe visible from the exterior of the perforations. Subsequently, anyreference to coupling of each of the plurality of sensors 30 to theperiphery of each perforation of the plurality of perforations 28 or ofeach of the plurality of sensors 30 being coupled to the periphery ofeach perforation of the plurality of perforations 28 includes embeddingat least a portion of the plurality of sensors 30 within the mountingplate 22.

Although FIG. 3A illustrates that each region includes three tubes, itshould be understood that a Region can include less than or more thanthree tubes, for example, two or five tubes. In some embodiments, eachperforation is being coupled with more than one sensor, for example twoor more sensors.

By shaping and dimensioning each perforation, for example, the firstperforation 28 d to enable, allow or facilitate fluid communication withthe first tube 12 d, the second tube 12 e and the third tube 12 f, thepresence of cleaning balls can be detected regionally. During a cleaningprocess, cleaning balls (not shown) passaging through at least one ofthe first tube 12 d, the second tube 12 e and the third tube 12 f can bedetected by a corresponding one of the plurality of sensors 30 (i.e.sensor 30 d). Similarly, cleaning balls passaging through at least oneof the fourth tube 12 g, the fifth tube 12 h and the sixth tube 12 i canbe detected by the second sensor 30 e. The configuration of FIG. 3Aprovides a method of detecting the cleaning balls regionally and itserves to notify and/or provide information relating to the passage ofballs in a particular region (i.e Region A or B).

FIG. 3B shows a first perforation 28 f of a detection device 20according to an embodiment of this disclosure. The first perforation 28f is shaped and dimensioned to enable, facilitate or allow fluidcommunication with a plurality of tubes, for example, the first tube 12j, the second tube 12 k and the third tube 12 l. The first perforation28 f is aligned such that any cleaning balls or liquid flowing throughthe first tube 12 j, the second tube 12 k and the third tube 12 l willbe able to flow or passage therethrough without being impeded or blockedby the first perforation 28 f. As such, during a heat exchange orcleaning operation, the fluid or cleaning ball is able to passagethrough the first tube 12 j, the second tube 12 k and the third tube 12l and perforation 28 f to other parts of the heat exchanger 10.

The first perforation 28 f has a plurality of sensors, namely, a firstsensor 30 f, a second sensor 30 g and a third sensor 30 h. Each of thesesensors, 30 f, 30 g and 30 h is one of coupled to and disposed on theperiphery of the first perforation 28 f. Each of the sensors, 30 f, 30 gand 30 h is aligned and/or positioned with respect to a tube, forexample, the first sensor 30 f is positioned on the periphery ofperforation 28 f in close proximity to the first tube 12 j, the secondsensor 30 g is positioned on the periphery of the first perforation 28 fin close proximity to the second tube 12 k and the third sensor 30 h ispositioned on the periphery of the first perforation 28 f in closeproximity to the third tube 12 l. The positioning of each of the sensors30 f, 30 g and 30 h is such that when a cleaning ball passages through atube, for example, the first tube 12 j, the corresponding first sensor,30 f detects the presence of the cleaning ball.

As will be appreciated by a person of ordinary skill in the art, thefirst perforation 28 f can be shaped and dimensioned to enable,facilitate or allow fluid communication with more than three tubes, forexample, four or more tubes.

In the foregoing embodiments, the plurality of sensors 30 is being oneof coupled to, is couplable to and disposed on the periphery of theplurality of perforations 28. The coupling and/or positioning of theplurality of sensors 30 to the plurality of perforations 28 is describedin greater detail in the following sections.

Coupling and/or Positioning of the Plurality of Sensors

FIGS. 4A and 4B show a top view and a side view of a detecting device20, respectively according to various embodiments of this disclosure. Asshown, the plurality of sensors 30 is one of coupled to and disposed onthe periphery of a corresponding perforation of the plurality ofperforations 28. Particularly, the plurality of sensors 30 is one ofcoupled to and disposed on at least a portion of the perimeter orcircumference of the plurality of perforations 28. In some embodiments,the plurality of sensors 30 is one of coupled to and disposed on atleast a portion of an inner surface of each perforation and theplurality of sensors 30 is substantially flushed with the top side 24 ofthe mounting plate 22.

FIGS. 5A and 5B show a top view and a side view of a detecting device20, respectively according to various embodiments of this disclosure. Ascan be seen in FIG. 5A, the plurality of sensors 30 are one of beingcoupled to and disposed on the periphery of the plurality ofperforations 28. In some embodiments, the plurality of sensors 30 iscoupled to or disposed on the top side 24 of the mounting plate 22.Depending upon embodiment details, the plurality of sensors 30 mayprotrude from a surface of the top side 24 of the mounting plate 22.

In some other embodiments, at least one of the plurality of sensors 30is formed with the mounting plate 22. For example, a recess can beformed on the mounting plate 22 to embed at least one of the pluralityof sensors 30.

Each of the plurality of sensors 30 being one of couplable to and formedwith the corresponding at least one of the perforations by way ofadhesive, embedding, sputtering, metal injection moulding, casting,compressing, printing and etching.

Sensor Characteristics and Operation

Each of the plurality of sensors 30 is being detectable in manydifferent ways, including but not limited to at least one ofelectromagnetic, acoustic-magnetic, magnetic resonance, inductivecoupling including antenna, infrared, eddy current, ultrasonic andpiezoelectric. The theory of Frustrated Total Internal Reflection (FTIR)can also be adopted for the plurality of sensors 30 and this will beexplained in detail later. Upon detection of the cleaning balls, thedetection signals will be further processed.

FIG. 6 shows a configuration of devices for processing of detectionsignals. The detecting device 20 can further comprise a manifold 32.Each sensor of the plurality of sensors 30 is electrically couplable tothe manifold 32, which in turn is electrically coupled to a processingunit 34 for processing of the sensed data or information. The manifold32 can be operable for one of receiving detection signals andelectronically communicating with the plurality of sensors 30. Thesignal coupling between each sensor and the manifold 32 is by way ofwired or wireless technology. The processing unit 34 can include asingle processing device or a plurality of processing devices. Such aprocessing unit 34 can be a microprocessor, micro-controller, digitalsignal processor, microcomputer, field programmable gate array,programmable logic device, logic circuitry, digital circuitry, analoguecircuitry and/or any other devices that is capable of manipulatingsignals. Memory (not shown) coupled to and/or embedded in the processorunit 34 may be a single memory device or a plurality of memory devices.Such a memory device can be a read-only memory, random access memory,volatile memory, static memory, dynamic memory, cache memory and/or anydevice that stores digital information. Depending upon embodimentdetails, the plurality of sensors 30 can communicate with the processingunit 34 in a wired or wireless manner with the latter adoptingtechnologies such as BLUETOOTH, Wi-Fi, 2G, 3G, RFID, acoustic, infraredand optical. In some embodiments, any processed detecting signals aredisplayed on a monitor 36. This enables a user of the detecting device20 to manipulate the processed detecting signals through the processingunit 34 by external or peripheral devices such as a computer keyboardand a computer mouse.

Frustrated Total Internal Reflection

Frustrated Total Internal Reflection (FTIR) is a technology that can beimplemented with the sensors of this disclosure. When light encountersan interface to a medium with a lower index of refraction, such as glassto air, the light becomes refracted to an extent that depends on itsangle of incidence. Beyond a critical angle, the light undergoes totalinternal reflection (TIR). If another material is placed at theinterface, total internal reflection must be frustrated thereby causinglight to escape the waveguide. This area of technology is well known andis readily understood by a person of ordinary skill in the art.

FIG. 7 shows an example of a detection device 10 in operation based uponFTIR according to some embodiments of this disclosure. The sensor 30 ican include a waveguide 38 and a detector 40. Light 42 emitted from alight source (not shown) undergoes total internal reflection, causingthe light 42 to be trapped within the waveguide 38. A cleaning ball 18travels along or through a tube 12. When the cleaning ball 18 comes intocontact with, touches or impacts the waveguide 38, light 42 that wastotally internally reflected is frustrated thus causing some light toescape from the waveguide 38. The frustrated or scattered light 44escapes from the optical waveguide 38 and is being detected by thedetector 40. In some embodiments, the detector 40 can be equipped with aband pass filter (not shown) to minimize optical noise. The detector 40is based upon one of charged-coupled device (CCD), complementarymetal-oxide-semiconductor (CMOS) technology and opto-electro transducer.

In some embodiments, the detector 40 can be wired to a computer or anyother electronic device capable of handling various well-known detectionprocessing.

Thus, there has been shown and discussed various embodiments of adetecting device for use with a heat exchanger which fulfils theobjectives and advantages sought thereof. Many changes, modifications,variations, and other uses and applications of the subject disclosurewill, however, become apparent to those skilled in the art afterconsidering this specification together with the accompanying figuresand claims. The same detection device, together with ensuing benefitsare also applicable to similar equipment in unrelated industries whereobjects must be detected so as to improve operating efficiencies. Allsuch changes, modifications, variations and other uses and applicationswhich do not depart from the spirit and scope of the detecting device ofthis disclosure are deemed to be covered by embodiments of thisdisclosure which is limited only by the claims which follows.

In the foregoing manner, various embodiments of the disclosure aredescribed for addressing at least one of the foregoing disadvantages.Such embodiments are intended to be encompassed by the following claims,and are not to be limited to specific forms or arrangements of parts sodescribed and it will be apparent to one skilled in the art in view ofthis disclosure that numerous changes and/or modification can be made,which are also intended to be encompassed by the following claims.

1. A detection device for use with a heat exchanger having a pluralityof tubes, the device comprising: a mounting plate couplable to theplurality of tubes, the mounting plate defining a plurality ofperforations, the plurality of perforations aligned with the pluralityof tubes, the plurality of perforations being shaped and dimensioned tofacilitate passage of at least one of a plurality of cleaning ballstherethrough; and a plurality of sensors, each sensor of the pluralityof sensors being coupled to at least one of the plurality ofperforations; wherein each of the plurality of tubes is operable with acorresponding one of the plurality of sensors and when the plurality ofcleaning balls is introduced into a portion of the heat exchanger forpassage through the plurality of tubes for cleaning thereof, eachcleaning ball passaging through one of the plurality of tubes isdetectable by the corresponding one of the plurality of sensors.
 2. Thedetection device of claim 1, the plurality of tubes defining twoextremities, the plurality of tubes defining a plurality of inlets atone of and a plurality of outlets at the other of the extremities. 3.The detection device of claim 2, the mounting plate being shaped anddimensioned for disposing onto one of the extremities of the pluralityof tubes.
 4. The detection device of claim 1, the mounting plate beingformed from at least one of plastic, graphene, rubber andpolytetrafluroethylene (PTFE).
 5. The detection device of claim 1, themounting plate having a thickness of between approximately 20 and 80 mm.6. The detection device of claim 1, wherein the plurality ofperforations include at least 3 perforations.
 7. The detection device ofclaim 1, each of the plurality of perforations being of any shape. 8.The detection device of claim 1, each of the plurality of sensors beingone of couplable to and formed with the corresponding at least one ofthe perforations by way of adhesive, embedding, sputtering, metalinjection moulding, casting, compressing, printing and etching.
 9. Thedetection device of claim 1, further comprising a manifold, the manifoldcouplable to the plurality of sensors for one of receiving detectionsignals and electronically communicating with the plurality of sensors.10. The detection device of claim 1, each of the plurality of ballsbeing detectable by the plurality of sensors by way of at least one offrustrated total internal reflection (FTIR), electromagnetic,acoustic-magnetic, magnetic resonance, inductive coupling includingantenna, infrared, eddy current, ultrasonic and piezoelectric.
 11. Thedetection device of claim 1, each of the plurality of sensors being oneof coupled to and disposed on the periphery of a correspondingperforation of the plurality of perforations.
 12. The detection deviceof claim 1, at least one of the plurality of sensors being embeddedwithin the mounting plate.
 13. The detection device of claim 1, themounting plate having a first planar surface and a second planar surfaceoutwardly opposing the first planar surface.
 14. The detection device ofclaim 10, at least one of the plurality of sensors being disposed on thefirst planar surface.
 15. A detection device for use with a heatexchanger having a plurality of tubes, the plurality of tubes beingdemarcated into a plurality of regions, each of the plurality of regionsincludes at least one tube, the device comprising: a mounting platecouplable to the plurality of tubes, the mounting plate defining aplurality of perforations, each of the plurality of perforations shapedand dimensioned to facilitate fluid communication with at least one tubeof each region, the plurality of perforations shaped and dimensioned tofacilitate passage of at least one of a plurality of cleaning ballstherethrough; and a plurality of sensors, each sensor of the pluralityof sensors being coupled to at least one of the plurality ofperforations; wherein each of the plurality of perforations is operablewith a corresponding one of the plurality of sensors and when theplurality of cleaning balls is introduced into a portion of the heatexchanger for passage through the plurality of tubes for cleaningthereof, each cleaning ball passaging through a tube of the plurality oftubes is detectable by the corresponding sensor of the perforation. 16.The detection device of claim 15, the mounting plate being formed fromat least one of plastic, graphene, rubber and polytetrafluroethylene(PTFE).
 17. The detection device of claim 15, wherein the plurality ofsensors being coupled to the at least one of the plurality ofperforations includes at least one sensor.
 18. The detection device ofclaim 15, further comprising a manifold, the manifold couplable to theplurality of sensors for one of receiving detection signals andelectronically communicating with the plurality of sensors.
 19. Thedetection device of claim 15, each of the plurality of balls beingdetectable by the plurality of sensors is by way of at least one offrustrated total internal reflection (FTIR), electromagnetic,acoustic-magnetic, magnetic resonance, inductive coupling includingantenna, infrared, eddy current, ultrasonic and piezoelectric.
 20. Thedetection device of claim 15, wherein each of the plurality of sensorsbeing one of coupled to and disposed on the periphery of a perforationof the plurality of perforations.